1. Introduction
Just 24 hours ago, a major architectural firm in Portland unveiled a new residential project featuring a striking corten steel facade that’s reigniting interest in metal clad exteriors among eco-conscious homeowners. With sustainability and industrial-chic aesthetics driving demand, more people are asking: how do you properly install and care for metal clad walls?
Whether you’re building a metal clad house from scratch or upgrading an existing structure with corrugated steel facade or vertical standing seam metal siding, this guide gives you actionable steps—and avoids costly mistakes.
2. Understanding Metal Clad Basics
Before diving into installation, it helps to know what ‘metal clad’ really means. The metal clad meaning refers to any construction surface covered with a layer of metal for protection, durability, or visual appeal. This includes everything from metal clad wall panels to metal clad roofing and even metal clad electrical wire—but here, we focus on exterior cladding.
Common types include:
- Corten steel siding (known for its rust-like patina)
- Zinc metal siding (low-maintenance and sleek)
- Copper siding (luxurious but expensive)
- Colorbond standing seam or PAC Clad standing seam roof systems
- Exterior corrugated metal siding (budget-friendly and rugged)
These materials fall under broader categories like clad metals, clad steel, or alloy clad—often made by bonding layers such as aluminum clad steel or stainless clad aluminum for enhanced performance.
3. Tools and Materials You’ll Need
Installing a metal clad wall isn’t DIY-simple, but with the right prep, it’s manageable. Gather these essentials:
- Measuring tape and chalk line
- Metal snips or sheet metal cutter
- Drill with metal-compatible bits
- Self-tapping screws with neoprene washers
- Underlayment (typically a breathable house wrap)
- Flashing and trim pieces (e.g., PAC Clad coping or column covers)
- Safety gear: gloves, goggles, and ear protection
Also confirm your chosen product specs—whether it’s a zinc clad dormer panel, aluminum clad sheet, or 1/8 inch steel plate—since thickness affects handling and fastening.
4. Step-by-Step Installation Guide
4.1. Prepare the Substrate
Your wall must be structurally sound, flat, and dry. Install a moisture barrier like Tyvek over plywood or OSB sheathing. Never attach metal directly to bare framing—it invites condensation and corrosion.
4.2. Plan Panel Layout
Start at a corner and work horizontally or vertically based on your design. For vertical standing seam metal siding, panels run floor-to-roof. Mark stud locations—you’ll need to screw into solid backing every 12–24 inches.
4.3. Cut and Fit Panels
Use metal sheet cutting tools to trim panels to size. Wear gloves—edges can be razor-sharp. For custom shapes (like around windows), score and bend rather than forcing cuts.
4.4. Secure Panels Properly
Fasten using corrosion-resistant screws designed for your metal type. Over-tightening cracks coatings; under-tightening causes rattling. Leave slight gaps (per manufacturer specs) for thermal expansion—especially critical with materials like corten steel plate or aluminum diamond tread plate.
4.5. Seal Joints and Edges
Apply compatible sealant at seams, corners, and penetrations. Use pre-finished trim like PAC Clad HWP for clean transitions. Don’t skip flashing above windows or below sills—it prevents water intrusion behind the metal clad wall.
5. Common Problems and Fixes
5.1. Rust or Corrosion on Steel Clad Surfaces
Even ‘weathering’ steel like corten needs time to stabilize. If you see premature rust on non-corten steel, clean with vinegar, then apply a zinc-coated primer. For long-term protection, consider electroplating or chrome carbide overlay in harsh climates.
5.2. Oil Canning (Wavy Distortion)
This happens when panels aren’t supported evenly. Solution: Add intermediate clips or use thicker gauge metal—like 3/16 steel plate instead of 1/8 inch steel plate—for large spans.
5.3. Fading or Chalking on Painted Systems
Colorbond and similar finishes degrade in UV-heavy areas. Wash annually with mild soap; repaint only with manufacturer-approved products to avoid voiding warranties.
6. Maintenance Tips for Longevity
Metal clad exteriors are low-maintenance but not zero-maintenance. Twice a year:
- Rinse with a garden hose to remove dust and pollutants
- Inspect fasteners for looseness
- Check seals around windows and doors
For copper or zinc facades, avoid abrasive cleaners—they strip natural patinas. And never power-wash corrugated steel facade panels; high pressure forces water behind seams.
7. Cost Considerations
Corten siding cost ranges from $8–$15/sq.ft., while zinc clad roof systems can exceed $20/sq.ft. Aluminum clad steel offers a middle ground. Always factor in labor—DIY saves money but risks improper installation that leads to leaks or structural issues.
8. Conclusion
A well-installed metal clad wall boosts curb appeal, resists fire and pests, and lasts decades. Whether you choose a bold corten steel facade, a sleek zinc metal siding, or budget-friendly exterior corrugated metal siding, following these steps ensures performance and beauty. Remember: the key isn’t just the metal—it’s how you clad it.
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